Environmental sensor, particle counting system having an environmental sensor, and methods of operating the same

ABSTRACT

An environmental sensor including an inlet and an outlet such that a flow of fluid moves from the inlet to the outlet, a particle detection portion to detect particles in the fluid, and a controller connected to the particle detection portion. The environmental sensor can be in communication with a data acquisition system (e.g., via a wireless access point) to form a particle counting system. Also disclosed are methods of operating the environmental sensor and methods of operating the particle detection system.

BACKGROUND

The invention relates to environmental sensors, such as particlecounters that are used to detect particles in air or liquidenvironments. The invention also relates to particle counting systemshaving an environmental sensor, methods of operating the particlecounting systems, and methods of operating the environmental sensor.

Particle detection, among other uses, allows for monitoring themanufacturing of a product that would be unsuitable for its intendedpurpose if contamination is present, even at the molecular level. Forexample, pharmaceutical manufacturers require environments that aresterile to avoid viable organisms from contacting a product beingmanufactured or packaged. Also, pharmaceutical manufacturers monitorspecified areas to insure compliance with cleanliness standards.

Another industry that generally requires the use of a particle countingsystem in an environment is the semiconductor manufacturing industry.Semiconductor manufacturers monitor the cleanliness of their processfluids, gasses, and environments to identify and eliminate sources ofcontamination. Other industries can use particle counting systems todetect and control contamination that affects product performance andquality. For example, manufacturers of automotive products, portableequipment, micro-machined structures, and optical assemblies may rely onthe use of particle counting systems for some of their manufacturingprocesses.

Accordingly, there is the need for an environmental sensor thatperforms, among other things, reliable particle counts and allows foraccess and distribution of information related to the particle counts.There is also a need for a particle counting system incorporating suchan environmental sensor.

SUMMARY

In one embodiment, the invention provides a method of operating aparticle counting system including an environmental sensor. Theenvironmental sensor includes a memory having a predetermined particlecount at a first memory address. The method comprises storing a detectedparticle count at a second memory address of the memory, receiving afirst signal, copying the predetermined particle count from the firstmemory address to the second memory address in response to receiving thefirst signal, and generating a second signal based on the second memoryaddress including the predetermined particle count.

In another embodiment, the invention provides a particle countingsystem. The particle counting system comprises a data acquisition systemconfigured to generate an information request, and an environmentalsensor configured to receive the information request. The environmentalsensor includes an inlet and an outlet such that a flow of fluid movesfrom the inlet to the outlet, a particle detection portion to detectparticles in the fluid, a memory including a first count at a firstmemory address, and a controller connected to the particle detectionportion. The controller is configured to generate a second count basedon the detected particles, store the second count at a second memoryaddress of the memory, and copy the first count from the first memoryaddress to the second memory address in response to the environmentalsensor receiving the information request.

In another embodiment, the invention provides a method of operating anenvironmental sensor including a memory. The method comprises creating aflow of fluid through the environmental sensor, detecting particles inthe fluid, determining a first particle count having a relation to thenumber of detected particles in a first time interval, determining asecond particle count having a relation to the number of detectedparticles in a second time interval, determining a third particle counthaving a relation to the number of detected particles in a third timeinterval, detecting a condition of the environmental sensor during oneof the first, second, and third time intervals, discarding therespective one of the first, second, and third particle counts inresponse to detecting the condition during one of the first, second, andthird time intervals, resulting in non-discarded particle counts, anddetermining a total particle count based on the non-discarded particlecounts.

In another embodiment, the invention provides an environmental sensor.The environmental sensor comprises an inlet and an outlet such that aflow of fluid moves from the inlet to the outlet, a particle detectionportion to detect particles in the fluid during a plurality of timeintervals, and a controller connected to the particle detection portion.The controller is configured to detect a condition of the environmentalsensor, determine particle counts corresponding to the plurality of timeintervals, and discard particle counts related to the time intervalswhen the condition of the environmental sensor is detected.

In another embodiment, the invention provides a particle countingsystem. The particle counting system includes an environmental sensorconfigured to receive an information request. The environmental sensorincludes an inlet and an outlet such that a flow of fluid moves from theinlet to the outlet, a particle detection portion to detect particles inthe fluid, and a memory including first memory address and a secondmemory address, the first memory address having a first count. Theparticle counting system also includes a controller connected to theenvironmental sensor over a network. The environmental sensor isconfigured to generate a second count based on the detected particles,and to store the second count at the second memory address. Thecontroller is configured to send the information request to theenvironmental sensor to copy the first count from the first memoryaddress to the second memory address in response to receiving theinformation request.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a particle counting system.

FIG. 2 is a schematic representation of a second particle countingsystem.

FIG. 3 is a schematic representation of a particle counter.

FIG. 4 is a partial schematic representation of the particle counterillustrated in FIG. 3.

FIG. 5 is a schematic representation of an alternative construction forthe controller illustrated in FIG. 4.

FIG. 6 is a schematic representation of an alternative construction forthe communication layer illustrated in FIG. 4.

FIG. 7 is a schematic representation of a data acquisition system.

FIG. 8 is an information display in the form of a webpage.

FIG. 9 is a schematic representation of a status register.

FIG. 10 is a table illustrating a plurality of memory addresses.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items.

Although directional references, such as upper, lower, downward, upward,rearward, bottom, front, rear, etc., may be made herein in describingthe drawings, these references are made relative to the drawings (asnormally viewed) for convenience. These directions are not intended tobe taken literally or limit the invention in any form. In addition,terms such as “first”, “second”, and “third” are used herein forpurposes of description and are not intended to indicate or implyrelative importance or significance.

In addition, it should be understood that embodiments of the inventioninclude hardware, software, and electronic components or modules that,for purposes of discussion, may be illustrated and described as if themajority of the components were implemented solely in hardware. However,one of ordinary skill in the art, and based on a reading of thisdetailed description, would recognize that, in at least one embodiment,the electronic based aspects of the invention may be implemented insoftware. As such, it should be noted that a plurality of hardware andsoftware based devices, as well as a plurality of different structuralcomponents, may be utilized to implement the invention. Furthermore, andas described in subsequent paragraphs, the specific mechanicalconfigurations illustrated in the drawings are intended to exemplifyembodiments of the invention and that other alternative mechanicalconstructions are possible.

FIG. 1 is a schematic representation of a particle counting system 10configured in a wireless access point topology. The particle countingsystem 10 includes an environmental sensor 15, a wireless access point(WAP) 20, and a data acquisition system (DAS) 25 connected to the WAP 20via a network 30. It is envisioned that the number of environmentalsensors 15, WAPs 20, etc. can vary from the construction shown.

In the illustrated construction, the environmental sensor 15 wirelesslycommunicates with the WAP 20 to send and receive information viawireless protocols (e.g., standard wireless protocols). The WAP 20 isconnected to the network 30 via a “wired” connection. In oneconstruction, the WAP 20 can include a NETGEAR WGR614 wireless router.The term “wired” is intended to define means of connection such as USBcable, DSL cable, Ethernet cable, and others. Similarly, the network 30is intended to broadly cover either a connection to the Internet or alsoan intranet or internal network. It is also envisioned that the network30 can include wireless connections. In addition to the specified DAS 25shown in FIG. 1, the particle counting system 10 can also include otherelements connected to the network 30, such as a computer 35.

FIG. 2 is a schematic representation of a particle counting system 40configured with an ad-hoc topology. More specifically, the particlecounting system 40 includes one or more environmental sensors 15 (onlyone environmental sensor 15 shown in FIG. 2) wirelessly connected to aDAS 25, which can alternatively be connected to a network 30. Inconstructions where the particle counting system 40 includes more thanone environmental sensor 15, each environmental sensor 15 includes anaddress which is recognized by the DAS 25. Each environmental sensor 15has a unique address that allows the DAS 25 to receive, store, andcommunicate information from the various environmental sensors 15, whichmay be located in distinct and remote environments. As used herein, theterm “information” is broadly construed to comprise signals (e.g.,analog signals, digital signals, etc.), states, data (e.g., packet data,non-packet data, etc.), etc., for providing knowledge, values, events,facts, measures, outcomes, and similar items.

With reference to FIGS. 1 and 2, the particle counting systems 10 and 40are configured to communicate information from the environmental sensor15 to the DAS 25 to exchange information regarding the space in whichthe environmental sensor 15 is located, also defined an environmentalzone (e.g., a “clean” zone). One difference between the particlecounting systems 10 and 40 is that, in the particle counting system 10,the DAS 25 can access the environmental sensor 15 remotely through thenetwork 30, and in the particle counting system 40, the DAS 25 directlyaccesses the environmental sensor 15 through a wireless connection. Itis to be understood, however, that the topologies and/or configurationsdescribed in FIGS. 1 and 2 are for exemplary purposes and that otherconfigurations of the particle counting system may fall within aspectsof the invention. For example, it is envisioned that the sensor 15 cancommunicate with the WAP 20 or the DAS 25 via wire means.

FIG. 3 is a schematic representation of an exemplary environmentalsensor. More specifically, the environmental sensor shown in FIG. 3 is aparticle counter 50 configured to detect particles within apredetermined size range. The particle counter 50 is an aerosol particlecounter that operates under the principle of light scattering detection.However, other aerosol particle counters (e.g., a particle counter thatoperates under the principle of light obscuration) and liquid particlecounters can be used, among others. The particle counter 50 includes afluid movement portion 55 and a control portion 60. The fluid movementportion 55 includes a fluid (e.g., air) inlet 65, a particle detectionportion 70, a vacuum source 75, a filter 80, and a fluid outlet 85.

In the construction shown in FIG. 3, a flow of air is created by thevacuum source 75 (e.g., an air pump or blower). The flow enters theparticle counter 50 through the inlet 65, as shown by arrows 90, andtraverses to the particle detection portion 70 where the portions 70detects particles in the air, as explained in more detail below. Theflow then traverses to the filter 80 and exits through the outlet 85. InFIG. 3, the vacuum source 75 is shown as being part of the flow path.However, other constructions of the particle counter 50 can include avacuum source not directly in the path of the flow or, alternatively,the particle counter 50 can include an external vacuum source.Similarly, FIG. 3 illustrates one filter 80 located near the outlet 85.However, other constructions of the particle counter 50 can include adifferent number of filters (including zero) and the location of thefilter may vary. In yet other constructions, the fluid movement portion75 can include a tube or hose with one end connected to the inlet 65such that the vacuum source (internal or external) generates a flow fromthe other end of the tube and through the particle counter 50 asexplained above.

The control portion 60 of the particle counter 50 includes a controller100 operable to control and operate the particle counter 50. The controlportion 60 also includes a power source 105, a flow sensor 110, a lightsource 115 (e.g., a laser beam generator), an optical detector 120, acommunication layer 125, a display system 130, and an I/O layer 135.During operation of the particle counter 50, the flow sensor 110 isoperable to generate a signal indicative of the mass of the air flowingthrough the particle counter 50. The signal generated by the flow sensor110 allows the controller 100 to operate the vacuum source 75 tomaintain a constant flow through the particle counter 50. For example,the controller 100 can operate the vacuum source 75 to maintain aconstant flow rate of 1 cubic foot per minute (ft³/m in), which issubstantially equal to 28.3 liters per minute (lt/min). However, thevacuum source 75 can generate other flow rates based on desiredparameters or the particular application of the particle counter 50. Inother constructions, the environmental sensor 50 can include an externalvacuum source not connected to the control portion 60 such that theexternal vacuum source is controlled independently with respect to thecontrol portion to generate a fluid flow through the particle counter50.

Still with reference to FIG. 3, the display system 130 includes amultiple light display to indicate the status of the particle counter50. More particularly, the display system 130 includes an “on/off” typedisplay related to the power source, an alarm system, a particle countinterval, the light source, and the flow status. For example, thedisplay system 130 can indicate whether the particle counter is on oroff, whether a fault related to the air flow or light source 115 isdetected, whether the counter 50 is detecting a particle, whether thelight source 115 is operating, and whether the flow rate remainsconstant. Other constructions of the particle counter 50 can include thedisplay system 130 with a different number and combination of lights, oralternatively a different display element (e.g., an LCD screen). Thoughnot particularly described, the I/O layer 135 illustrates alternativeinput/output connections, displays, and/or switches allowing a user tocontrol and/or interact with the particle counter 50.

During operation of the particle counter 50, particles are detected bylight scattering. More specifically, the light source 115 generates alaser beam 140 within the particle detection portion 70 of the particlecounter 50. Particles flow through the particle detection portion 70, asshown by arrow 145, and through the laser beam 140. The particlestraversing the particle detection portion 70 result in light scattering(represented by 150), which is detected by the optical detector 120. Theoptical detector 120 generates a voltage pulse as a result of detectingthe light scattering 150 and sends the voltage pulse to the controller100. The controller 100 is operable to determine information regardingthe particles (e.g., particle size, velocity, composition) based on thevoltage pulse generated by the optical detector 120. The informationdetermined by the controller 100 can be saved in memory and/or sent tothe DAS 25, for example, by the communication layer 125 of the particlecounter 50.

FIG. 4 is a schematic representation of the control portion 60 as itrelates more specifically to the detection of particles, and to theprocessing and transmitting of information related to the detectedparticles. Accordingly, FIG. 4 illustrates in more detail the opticaldetector 120, the controller 100, and the communication layer 125. Thevacuum source 75, power source 105, flow sensor 110, light source 115,display system 130, and I/O layer 135 are also shown connected to thecontroller 100 for illustration purposes. The optical detector 120includes a photo detector and optics 155 to detect the scattering light150, and an amplifier 160 to generate a voltage pulse as a result ofdetecting the scattering 150. The controller 100 includes additionalamplifiers 165, a processor 170, and a memory 175. The processor 170includes an analog-to-digital converter (A/D) 180 and a pulse heightanalyzer or voltage comparator 185. The processor 170 may take the formof a microprocessor, a digital signal processor, a microcontroller, orsimilar devices that can execute instructions. Of course, the A/Dconverter 180 and/or voltage comparator 185 can be distinct from theprocessor 170, and the memory 175 can be combined with the processor170.

The voltage pulse generated by the optical detector 120 is received forprocessing at the controller 100 by the amplifier(s) 165 and theprocessor 170. More specifically, the amplifier(s) 165 can amplify andfilter the voltage pulse, and the A/D 180 can transform the voltagepulse into a digital signal for the voltage comparator 185 to analyze.The voltage comparator 185 analyzes the digital signal by comparing thesignal to predetermined values or voltage thresholds. Based on thecomparison, the processor 170 can determine whether the voltage pulsewas greater than a voltage threshold, for example, and save theinformation in the memory 175. As the controller 100 receives pulsesgenerated by the optical detector 120, a count of particles withpredetermined characteristics (e.g., particle size) can be stored in thememory 175.

FIG. 5 is a schematic representation of a controller 100A, which is analternative construction of the controller 100 shown in FIG. 4. Thecontroller 100A includes the amplifier(s) 165 and the memory 175. Thecontroller 100A also includes a processor 170A with a voltage comparator185A that compares analog voltage pulses generated by the opticaldetector 120 (not shown in FIG. 5). Accordingly, the controller 100Aanalyses and determines particle size information based on analogsignals, whereas the controller 100 analyzes and determines particlesize information based on digital signals.

In one exemplary construction of the particle counter 50, two particlecounts are stored in the memory 175. The first particle count is a countof particles with a size greater than 0.5 microns. The second particlecount is a count of particles with a size greater than 5 microns. Inother constructions, a different particle counts can be stored in thememory 175. The voltage thresholds related to each particle size (e.g.,0.5 microns and 5 microns) are determined through a calibration processof the particle counter 50. The calibration process can include creatingan aerosol cloud of particles with a known size, such as 0.5 microns or5 microns, and allowing the aerosol cloud to flow through particlecounter 50. The DAS 25 can be used in the calibration process to observethe particle size detected by the particle counter 50 such that anoperator can adjust the particle counter 50 until the correctinformation is generated. Though the particle counter 50 can becalibrated to detect a wide range of particle sizes, the particlecounter 50 is usually calibrated to sense particles with a size of 0.5microns and 5 microns because 0.5 microns relates to a specificcleanliness level for a clean zone, and 5 microns relates to the size ofbacteria or similar elements that are of interest for a clean zone.

Referring again to FIG. 4, the communication layer 125 includes aprocessor 190, a memory 195, a modulator/demodulator circuit 200, and anantenna 205. In one exemplary construction of the particle counter 50,the communication layer 125 includes a Digi Connect wireless module toallow communication between the particle counter 50 and a second device.More specifically, the communication layer 125 receives the particlesize information from the controller 100 and is operable to wirelesslytransmit the information to the WAP 20, as shown in FIG. 1, or directlyto the DAS 25 in an ad-hoc topology, as shown in FIG. 2. In someconstructions, the communication layer 125 can include a web page designstored in the memory 195, be operable to combine particle countinformation and/or status information (of the particle counter 50) withthe web page design, and transmit the combined information. Thecommunication layer 125 also receives information and/or instructions tooperate the particle counter 50. For example, the communication layer125 can receive particle count requests from the DAS 25 or a statusrequest from a computer (e.g., computer 35 shown in FIG. 1).

FIG. 6 is a schematic representation of a communication layer 125A,which is an alternative construction of the communication layer 125shown in FIG. 4. The communication layer 125A includes the processor 190and the memory 195. The communication layer 125A also includes a wireconnector, such as an RJ-45 connector 210, for communication withanother device or network. In yet another construction, the particlecounter 50 can include a communication layer that is integrallymanufactured with a controller. The controller would then be operable tocontrol and communicate as described in regards to the controller 100and the communication layers 125 or 125A.

FIG. 7 is a schematic representation of the DAS 25 shown in FIGS. 1 and2. In the illustrated construction, the DAS 25 includes a computersystem 215 having a processor 220, a communication layer 225, a memory230, a display system 235, and an I/O layer 240. The computer system 215is described herein as it relates to the particle counter 50. However,the computer system 215 can communicate with other devices, such as thesensing devices illustrated in FIG. 7. The sensing devices can include atemperature sensor 245, a humidity sensor 250, and a pressure sensor255.

With reference to FIGS. 1, 2 and 7, the DAS 25 is configured tocommunicate with the environmental sensor 15 to send information, suchas control commands or data requests, and to receive information, suchas particle counts and status of the environmental sensor 15. In theillustrated construction, the DAS 25 includes a set of instructionsidentified as a driver 260 that are designed specifically to operate theenvironmental sensor 15. For example, the driver 260 can take datacollected by the particle counter 50, and alternatively take data fromother sensors such as the temperature sensor 245, humidity sensor 250,and pressure sensor 255, and send the data to a database for storage.The driver 260 can also transfer the data to a memory location where itcan be retrieved for further processing. Processing of the data by theDAS 25 can include comparing the data to predetermined thresholds and topresent the data through the display system 235 in a manner that issignificant to the user. The driver 260 can also include instructions tooperate specific elements of the particle counter 50. For example, thedriver 260 can individually operate and monitor the vacuum source 75,light source 115, and display system 130.

In the constructions shown in FIGS. 1 and 2, the particle countingsystem 10, 40 can include the particle counter 50 calibrated to detectparticles with a size larger than 0.5 microns. Further, the computersystem 215 with the driver 260 can be configured to move data related toparticle counts to specific memory addresses in the particle counter 50,to retrieve data related to particle counts combined with web pageinformation from the communication layer 125, and to display theretrieved data with the display system 235. FIG. 8 is an exemplaryinformation display 265 generated by the display system 235. Theinformation display 265 displays various information, which may includesystem information 270, status information 275, and count information280. The information display 265 is illustrated in the form of a webpageaccessed by the computer system 215 though the network 30, for example.Because the communication layer 125 of the particle counter 50 caninclude web page design information, the display 265 can take the formof the webpage shown in FIG. 8 when the particle counter 50 and computersystem 215 are in an ad-hoc topography, as shown in FIG. 2. The systeminformation 270 refers to the specific type of particle counter 50 andnetwork connection. The status information 275 refers to the status ofthe particle counter 50 as well as the status of specific elements ofthe particle counter 50, such as the light source 115 and vacuum source75. The count information 280 refers to data detected by the particlecounter 50, such as flow rate and particle counts.

FIG. 9 is a schematic representation of the status information 275stored in a memory location of the memory 175. More specifically, thestatus information 275 is shown in a first memory address 285 and asecond memory address 290, each address being a 16-bit memory address.For the computer system 215 to display the status information 275, thedriver 260 needs only to retrieve information in memory addresses 285,290. The computer system 215 matches specific bits of the memoryaddresses 285, 290 to the status of a corresponding element of theparticle counter 50, and displays the status information 275 (e.g.,light source being on or off) accordingly. FIG. 10 is a schematicrepresentation of the memory 175 including a number of memory addresses300 dedicated to different types of counts and information related tothe particle counter 50 (e.g., status information). With specificreference to the count information 280, the driver 260 retrieves thecount information 280 from specific memory addresses (e.g., memoryaddresses 12 and 13) in the memory 175 of the particle counter 50. Thecomputer system 215 is operable to display the count information 280(e.g., the number of particles with particle size larger than 0.5microns) as a result of retrieving the count from a dedicated memoryaddress in memory 175. Therefore, size information of the particle isnot sent or generated by the particle counter 50. The display system 235can display size information with the count information 280 based on theknown calibration of the particle counter 50 and the dedicated addressin the memory 175 where the count information 280 was retrieved.Similarly, status information 275 can be retrieved from a specificaddress in the memory 175 of the particle counter 50. As a result, datatransfer between the particle counter 50 and the computer system 215 isimproved.

With specific reference to the operation of the particle counter 50, theparticle counter 50 is calibrated to establish, among other parameters,the size of the particles to be detected and the flow rate. As indicatedabove, the particle counter 50 can be calibrated to detect particles oftwo particle sizes (e.g., particle size larger than 0.5 microns andparticle size larger than 5 microns). The particle counter 50 is alsocalibrated to have a substantially constant flow rate. For example, theparticle counter 50 can be calibrated to generate a flow rate of about 1ft³/min (about 28.3 lt/min). In other constructions, the particlecounter 50 can be calibrated to generate different flow rates, such as25 lt/min, 50 lt/min, 75 lt/min, and 100 lt/min. Based on the calibratedflow rate, it is possible to determine the amount of time it takes forthe particle counter 50 to sample the complete volume of a clean zone.For analysis purposes, predetermined sample volumes are established suchthat a particle count can be displayed as a function of a standard unitof volume (e.g., 1 m³ or 1 ft³. Accordingly, for a particle counter 50calibrated to generate a flow rate of 1 ft³/min, it is determined thatthe particle counter 50 can sample a sample volume of 1 m³ in about 35.3minutes, and a sample volume of 1 ft³ in about 1 minute.

In the illustrated construction, the particle counter 50 is furtherconfigured to sample a sample volume in intervals. More specifically,the particle counter 50 is configured to sample a sample volume in sixtyintervals. Accordingly, if the sample volume is established to be 1 m³,the particle counter 50 can sample 1/60 m³ in about 35.3/60 minutes.Similarly, if the sample volume is established to be 1 ft³, the particlecounter 50 can sample 1/60 ft³ in about one second. Based on theapplication and/or desired characteristics of the particle counter 50,other constructions can include the particle counter 50 being calibratedto sample full sample volumes with a different number of intervals.Sampling the sample volume using time intervals allows the particlecounter 50 to store information related to partial counts in the memory175. For example, the memory 175 can include dedicated memory addresses(e.g., memory addresses 300) for partial count information, such as thenumber of particles for one time interval or the total particle countretrievable by the DAS 25 before the full sample volume has been sampledor the particle count for a previously completed sample. In addition,sampling the sample volume using intervals allows the particle counter50 to include operational features, defined as rolling counts, forcedcounts, and fault detection/salvaging data.

Rolling Counts

The rolling counts feature allows the particle counter 50 to determineand store a particle count for the most recent sample volume. Morespecifically, the rolling counts feature is implemented by the particlecounter 50 continuously adding the particle counts of time intervals. Asindicated above, once sixty time intervals have elapsed, the particlecount of the full sample volume is available at a predetermined memoryaddress 300. As the particle counter 50 continues to sample the cleanzone, the particle counter 50 uses the particle count taken during thelatest interval and discards the particle count taken from the oldestinterval to update the particle count of the full sample volume.Consequently, the particle count saved in the memory addresscorresponding to the particle count of the full sample volume is thecount obtained during the most recent sample volume. In the illustratedconstruction, memory addresses 300 identified as 0 and 1 in FIG. 10correspond to the particle count of the full sample volume for particleslarger than 0.5 microns. Similarly, memory addresses 300 identified as 2and 3 in FIG. 10 correspond to the particle count of the full samplevolume for particles larger than 5 microns.

Forced Counts

The forced counts feature allows the DAS 25 to utilize the particlecounter 50 to test the operation of the programming logic of the DASunder fault conditions. The forced counts feature also tests an alarmsystem (not shown) that actuates as a result of a fault condition, or asa result of comparing the particle counts obtained from the particlecounter 50 to predetermined threshold values. As shown in FIG. 10,memory addresses 300 defined by numerals 26 through 51 correspond toforced count information saved in the memory 175. More specifically, thedriver 260 of the DAS 25 includes instructions to command the particlecounter to take information from addresses 300 dedicated to forced countinformation and copy (also sometimes referred to as move) theinformation to corresponding memory addresses 300 where actual ordetected information is saved during operation of the particle counter50. The driver 260 then reads the information from the memory 175 as ifthe DAS 25 is retrieving actual detected information. In one example, ifa user tests for actuation of an alarm when the particle count of asample volume is larger than a predetermined threshold, the driver 260commands the particle counter to take the count from memory addresses300 corresponding to forced count information, and copy the informationto the memory addresses 300 where the particle count is saved duringoperation of the particle counter 50, and retrieves the information tothe DAS 25. The test is considered successful when the alarm isactivated as a result of the DAS 25 receiving and processing the forcedcount information. As shown in FIG. 10, every memory address 300 thatincludes forced count information has a corresponding memory address 300that includes information stored during operation of the particlecounter 50.

Alternatively, an auxiliary computer or controller (e.g., computer 35 ofthe particle counting system 10 illustrated in FIG. 1) other than theDAS may be equipped with a program operable to control the particlecounter and communicate with the particle counter over the network. Inthis scenario, the auxiliary computer sends commands to cause theparticle counter to send forced counts and status information to the DASunder test. The DAS programming is tested in this scenario without thenecessary test programs being run in the DAS itself.

Fault Detection/Data Salvaging

The fault detection feature allows the particle counter 50 to provideaccurate, as well as timely count information. More specifically, theparticle counter 50 can detect a fault condition and can react to thefault condition such that the particle count information is uncorrupted.The particle counter 50 can detect fault conditions such as malfunctionof the light source 115 or air flow interruption, for example. In thecase of a fault condition, the memory address corresponding to statusinformation 275, as shown in FIG. 9, are updated. Consequently, theparticle counter 50 discards the count information obtained in theinterval during which the fault condition occurred. Once the statusinformation 275 indicates the fault condition does not exist, theparticle counter 50 updates the total particle count with the countsdetected in the interval during which the fault condition is no longerdetected. This procedure allows the particle counter 50 to provide countinformation for a full sample volume without having to discard all thecounts corresponding to that sample volume in the situation where afault condition is detected. For example, if the sample volume isdetermined to be 1 ft³ and a fault condition was detected during one ofthe sixty intervals, the particle counter 50 can provide with a particlecount of the full sample volume in about 61 seconds (one additionalsecond than the case in which no fault condition is detected).Accordingly, the count detected during one faulty interval is discardedinstead of discarding the particle count determined for the whole samplevolume.

Various features and advantages of the invention are set forth in thefollowing claims.

1. A particle counting system comprising: a data acquisition systemconfigured to generate an information request; and an environmentalsensor configured to receive the information request, the environmentalsensor including an inlet and an outlet such that a flow of fluid movesfrom the inlet to the outlet, a vacuum source operable to create theflow of fluid between the inlet and the outlet, a particle detectionportion to detect particles in the fluid, a memory including a firstcount at a first memory address, and a controller connected to theparticle detection portion, the controller being configured to generatea second count based on the detected particles, store the second countat a second memory address of the memory, and copy the first count fromthe first memory address to the second memory address in response to theenvironmental sensor receiving the information request.
 2. The particlecounting system of claim 1, wherein the vacuum source is in a spacewithin the environmental sensor and is connected to the controller. 3.The particle counting system of claim 1, wherein the environmentalsensor further includes a communication layer operable to receive theinformation request and to generate a signal based on the first count inthe second memory address.
 4. The particle counting system of claim 3,wherein the communication layer includes an antenna to wirelesslyreceive a signal including the information request and send the signalbased on the first count.
 5. The particle counting system of claim 4,wherein the communication layer includes display information, andwherein the communication layer is configured to combine and wirelesslytransmit the display information with the signal based on the firstcount.
 6. The particle counting system of claim 3, wherein the dataacquisition system includes an alarm configured to generate a warning inresponse to the data acquisition system receiving the signal based onthe first count.
 7. The particle counting system of claim 1, furthercomprising a wireless access point, the environmental sensor wirelesslycommunicating the first count in the second memory address to the dataacquisition system via the wireless access point.
 8. A particle countingsystem comprising: an environmental sensor configured to receive aninformation request, the environmental sensor including an inlet and anoutlet such that a flow of fluid moves from the inlet to the outlet, aparticle detection portion to detect particles in the fluid, and amemory including a first memory address and a second memory address, thefirst memory address having a first count; a vacuum source operable tocreate the flow of fluid between the inlet and the outlet; and acontroller connected to the environmental sensor over a network, theenvironmental sensor being configured to generate a second count basedon the detected particles, and to store the second count at the secondmemory address, and the controller being configured to send theinformation request to the environmental sensor to copy the first countfrom the first memory address to the second memory address in responseto receiving the information request.
 9. The particle counting system ofclaim 8, wherein the vacuum source is in a space within theenvironmental sensor and is operated by the controller.
 10. The particlecounting system of claim 8, wherein the environmental sensor furtherincludes a communication layer operable to receive the informationrequest and to generate a signal based on the first count in the secondmemory address.
 11. The particle counting system of claim 10, whereinthe communication layer includes an antenna to wirelessly receive asignal including the information request and send the signal based onthe first count.
 12. The particle counting system of claim 11, whereinthe communication layer includes display information, and wherein thecommunication layer is configured to combine and wirelessly transmit thedisplay information with the signal based on the first count.
 13. Theparticle counting system of claim 10, further comprising an alarmconfigured to generate a warning in response to the controller receivingthe signal based on the first count.
 14. The particle counting system ofclaim 8, further comprising a wireless access point to connect theenvironmental sensor to the network, the environmental sensor wirelesslycommunicating the first count in the second memory address to thecontroller via the wireless access point.
 15. A particle counting systemcomprising: a data acquisition system configured to generate aninformation request; and an environmental sensor configured to receivethe information request, the environmental sensor including an inlet andan outlet such that a flow of fluid moves from the inlet to the outlet,a particle detection portion to detect particles in the fluid, a memoryincluding a first count at a first memory address, a controllerconnected to the particle detection portion, the controller beingconfigured to generate a second count based on the detected particles,store the second count at a second memory address of the memory, andcopy the first count from the first memory address to the second memoryaddress in response to the environmental sensor receiving theinformation request, and a communication layer operable to receive theinformation request and to generate a signal based on the first count inthe second memory address.
 16. The particle counting system of claim 15,wherein the vacuum source is in a space within the environmental sensorand is connected to the controller.
 17. The particle counting system ofclaim 15, wherein the communication layer includes an antenna towirelessly receive a signal including the information request and sendthe signal based on the first count.
 18. The particle counting system ofclaim 17, wherein the communication layer includes display information,and wherein the communication layer is configured to combine andwirelessly transmit the display information with the signal based on thefirst count.
 19. The particle counting system of claim 15, wherein thedata acquisition system includes an alarm configured to generate awarning in response to the data acquisition system receiving the signalbased on the first count.
 20. The particle counting system of claim 15,further comprising a wireless access point, the environmental sensorwirelessly communicating the first count in the second memory address tothe data acquisition system via the wireless access point.
 21. Aparticle counting system comprising: an environmental sensor configuredto receive an information request, the environmental sensor including aninlet and an outlet such that a flow of fluid moves from the inlet tothe outlet, a particle detection portion to detect particles in thefluid, and a memory including a first memory address and a second memoryaddress, the first memory address having a first count; a controllerconnected to the environmental sensor over a network, the environmentalsensor being configured to generate a second count based on the detectedparticles, and to store the second count at the second memory address,and the controller being configured to send the information request tothe environmental sensor to copy the first count from the first memoryaddress to the second memory address in response to receiving theinformation request; and wherein the environmental sensor furtherincludes a communication layer operable to receive the informationrequest and to generate a signal based on the first count in the secondmemory address.
 22. The particle counting system of claim 21, whereinthe vacuum source is in a space within the environmental sensor and isoperated by the controller.
 23. The particle counting system of claim21, wherein the communication layer includes an antenna to wirelesslyreceive a signal including the information request and send the signalbased on the first count.
 24. The particle counting system of claim 23,wherein the communication layer includes display information, andwherein the communication layer is configured to combine and wirelesslytransmit the display information with the signal based on the firstcount.
 25. The particle counting system of claim 21, further comprisingan alarm configured to generate a warning in response to the controllerreceiving the signal based on the first count.
 26. The particle countingsystem of claim 21, further comprising a wireless access point toconnect the environmental sensor to the network, the environmentalsensor wirelessly communicating the first count in the second memoryaddress to the controller via the wireless access point.